Automatic measurement of dimensional data with a laser tracker

ABSTRACT

Measuring with a system having retroreflector targets and a laser tracker includes storing a list of nominal coordinates for three targets and at least one added point; capturing on a photosensitive array of the tracker a portion of the light emitted by a light beam and reflected off the three targets; obtaining spot positions on a photosensitive array of a tracker camera from light reflected off the three targets; determining a correspondence between three spot positions on the tracker photosensitive array and the nominal coordinates of the three targets; directing a beam of light from the tracker to the three targets based at least in part on the nominal coordinates of the first target and the first spot position; measuring 3-D coordinates of the three targets with the tracker; determining 3-D coordinates of the at least one added point based at least in part on the measured 3-D coordinates of the three targets and the nominal coordinates of the at least one added point.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a divisional application of U.S. patentapplication Ser. No. 13/418,899 filed Mar. 13, 2012 which claims thebenefit of U.S. Provisional Patent Application No. 61/452,314 filed Mar.14, 2011, the entire contents of which are hereby incorporated byreference. The present application also claims the benefit of U.S.patent application Ser. No. 13/340,730 filed Dec. 30, 2011, which claimsthe benefit of U.S. patent application Ser. No. 13/090,889 filed Apr.20, 2011, which claims the benefit of U.S. Provisional PatentApplication No. 61/326,294 filed Apr. 21, 2010, the entire contents ofall of which are hereby incorporated by reference. The presentapplication also claims the benefit of U.S. Provisional PatentApplication No. 61/475,703 filed Apr. 15, 2011, the entire contents ofwhich are hereby incorporated by reference. The present application alsoclaims the benefit of U.S. Provisional Patent Application No. 61/592,049filed Jan. 30, 2012, the entire contents of which are herebyincorporated by reference. The present application also claims thebenefit of U.S. patent application Ser. No. 13/407,983 filed Feb. 29,2012, which claims the benefit of U.S. Provisional Patent ApplicationNo. 61/448,823 filed Mar. 3, 2011, the entire contents of both of whichare hereby incorporated by reference.

FIELD OF INVENTION

The present disclosure relates to metrology devices, such as, forexample, a laser tracker, and more particularly to a laser tracker thatautomatically identifies each of a plurality of retroreflector targetsplaced on an object using one or more locator cameras associated with(e.g., as part of) the laser tracker.

BACKGROUND

There is a class of instruments known as a laser tracker that measuresthe coordinates of a point by sending a laser beam to a retroreflectortarget in contact with the point. The instrument determines thecoordinates of the point by measuring the distance and the two angles tothe target. The distance is measured with a distance-measuring devicesuch as an absolute distance meter or an interferometer. The angles aremeasured with an angle-measuring device such as an angular encoder. Agimbaled beam-steering mechanism within the instrument directs the laserbeam to the point of interest.

The laser tracker is a particular type of coordinate-measuring devicethat tracks the retroreflector target with one or more laser beams itemits. There is another category of instruments known as total stationsor tachymeters that may measure a retroreflector or a point on adiffusely scattering surface. Laser trackers, which typically haveaccuracies on the order of a thousand of an inch and as good as one ortwo micrometers under certain circumstances, are usually much moreaccurate than total stations. The broad definition of laser tracker,which includes total stations, is used throughout this application.

Ordinarily the laser tracker sends a laser beam to a retroreflectortarget that is typically located on the surface of an object to bemeasured. A common type of retroreflector target is the sphericallymounted retroreflector (SMR), which includes a cube-cornerretroreflector embedded within a metal sphere. The cube-cornerretroreflector includes three mutually perpendicular mirrors. Thevertex, which is the common point of intersection of the three mirrors,is located near the center of the sphere. Because of this placement ofthe cube corner within the sphere, the perpendicular distance from thevertex to any surface of the object on which the SMR rests remainsnearly constant, even as the SMR is rotated. Consequently, the lasertracker can measure the 3D coordinates of a surface by following theposition of an SMR as it is moved over the surface. Stated another way,the laser tracker needs to measure only three degrees of freedom (oneradial distance and two angles) to fully characterize the 3D coordinatesof a surface.

Some laser trackers have the ability to measure six degrees of freedom(DOF), which may include three translations, such as x, y, and z, andthree rotations, such as pitch, roll, and yaw. An exemplary six-DOFlaser tracker system is described in U.S. Pat. No. 7,800,758 ('758) toBridges, et al., incorporated by reference herein. The '758 patentdiscloses a probe that holds a cube corner retroreflector, onto whichmarks have been placed. A retroreflector onto which such marks have beenplaced is called a six-DOF retroreflector. The cube cornerretroreflector is illuminated by a laser beam from the laser tracker,and the marks on the cube corner retroreflector are captured by a camerawithin the laser tracker. The three orientational degrees of freedom,for example, the pitch, roll, and yaw angles, are calculated based onthe image obtained by the camera. The laser tracker measures a distanceand two angles to the vertex of the cube-corner retroreflector. When thedistance and two angles, which give three translational degrees offreedom of the vertex, are combined with the three orientational degreesof freedom obtained from the camera image, the position of a probe tip,arranged at a prescribed position relative to the vertex of the cubecorner retroreflector, can be found. Such a probe tip may be used, forexample, to measure the coordinates of a “hidden” feature that is out ofthe line of sight of the laser beam from the laser tracker.

One common application of a laser tracker is to measure a relativelylarge object to see how its actual dimensions compare to the designdimensions (e.g., as given by CAD data). There may be several of theseobjects utilized in a particular application and the objects aretypically expected to be identical in geometry. Any distortion in thegeometry of the object either initially or developed over time caninfluence other operations in the overall system that the object is apart of. For example, if the object is bent or twisted in any way it canlead to manufacturing defects and poor product quality.

Typically as known at least three points are required to establish therelationship between the laser tracker and the object for measurementpurposes. As is known in the art, the ability of the operator tomanually measure these initial points with sufficient accuracy is anarea for consideration.

Thus, there is a need for an operator of a laser tracker or similarmeasurement device to be able to not have to manually measure thetargets points (e.g., SMRs). Instead, it would be desirable for theoperator of the laser tracker to utilize the camera system in the lasertracker to automatically measure all of the target points required forany particular application, thereby significantly reducing thepossibility of operator error in the measurement process and notrequiring specialized skills and/or training.

More generally, there is a need for a method and a system in which thelaser tracker automatically carries out many of the functions that wouldpreviously have to be carried out manually. It would be desirable toquickly obtain consistent measurements with the laser tracker, even ifthe measurements are carried out by an unskilled operator. Typicalmeasurements include tool inspection measurements; for example, thecarriage in a body-in-white assembly line is an example of a tool to beinspected or monitored. Other examples of tools include a sheet metalstamping jig, and an assembly tool for assembling a portion of anaircraft structure. Generally, for almost every part made in anautomotive or aerospace application, there is a corresponding tool.Thus, it would be desirable to improve the process of measuring suchtools with a laser tracker. In addition, it would be desirable to applythe measurement process to finished parts as well.

SUMMARY

A method for measuring with a system includes the steps of: providingthe system including a collection of retroreflector targets and a lasertracker, the collection of retroreflector targets including at leastthree non-collinear retroreflector targets, the at least threenon-collinear retroreflector targets including a first target, a secondtarget, and a third target, the laser tracker in a first frame ofreference fixed with respect to tracker surroundings, the laser trackerhaving a structure, a first light source, an absolute distance meter, afirst angular transducer, a second angular transducer, a trackingsystem, a first camera, a second light source, and a processor, thestructure rotatable about a first axis and a second axis, the firstlight source producing a first light beam that cooperates with theabsolute distance meter, the first angular transducer measuring a firstangle of rotation about the first axis, the second angular transducermeasuring a second angle of rotation about the second axis, the trackingsystem configured to move the first light beam to a center of anyretroreflector target from among the collection of retroreflectortargets, the first camera including a first lens system and a firstphotosensitive array, the second light source providing a second lightbeam, and the processor configured to operate the laser tracker; storinga list of nominal coordinates for the first target, the second target,the third target, and at least one additional point, the nominalcoordinates being three-dimensional coordinates in a second frame ofreference; capturing on the first photosensitive array a portion of thelight emitted by the second light beam and reflected off the firsttarget, the second target, and the third target; obtaining spotpositions on the photosensitive array from the portion of lightreflected off each of the first target, second target, and the thirdtarget; determining a correspondence between a first spot position, asecond spot position, and a third spot position on the firstphotosensitive array and the nominal coordinates of the first target,the second target, and the third target, respectively; directing thefirst beam of light to the first target based at least in part on thenominal coordinates of the first target and the first spot position;measuring three-dimensional coordinates of the first target using theabsolute distance meter, the first angular transducer, and the secondangular transducer; directing the first beam of light to the secondtarget based at least in part on the nominal coordinates of the secondtarget and the second spot position; measuring three-dimensionalcoordinates of the second target using the absolute distance meter, thefirst angular transducer, and the second angular transducer; directingthe first beam of light to the third target based at least in part onthe nominal coordinates of the third target and the third spot position;measuring three-dimensional coordinates of the third target using theabsolute distance meter, the first angular transducer, and the secondangular transducer; determining three-dimensional coordinates of the atleast one additional point in the first frame of reference based atleast in part on the measured three-dimensional coordinates of the firsttarget, the second target, the third target, and the nominal coordinatesof the at least one additional point; and storing the determinedthree-dimensional coordinates of the at least one additional point.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the drawings, exemplary embodiments are shown whichshould not be construed to be limiting regarding the entire scope of thedisclosure, and wherein the elements are numbered alike in severalFigures:

FIG. 1 is a perspective view of a laser tracker, an auxiliary unit, andan external computer according to an embodiment;

FIG. 2 is a perspective view of the laser tracker of FIG. 1 with anadditional narrow field of view camera and associated light sourceaccording to an embodiment;

FIG. 3 illustrates a two-dimensional representation of athree-dimensional vector diagram;

FIG. 4A is a front view of a wide-field locator camera disposed on arigid structure portion of the laser tracker of FIG. 1 where the rigidstructure is rotated to enable the locator camera to simultaneously viewplural retroreflector targets;

FIG. 4B is a cross sectional view of the locator camera of FIG. 4A takenalong line 410-410 of FIG. 4A;

FIG. 5A is a perspective view of the laser tracker of FIG. 1 in a firstorientation with respect to an object to be measured with the lasertracker automatically taking measurements of various target points onthe object;

FIG. 5B is a perspective view of the laser tracker of FIG. 1 in a secondorientation with respect to an object to be measured with the lasertracker automatically taking measurements of various target points onthe object;

FIG. 6 shows electronic processor elements within a laser trackeraccording to an embodiment;

FIG. 7 is a flow diagram showing steps in measuring with a systemaccording to an embodiment;

FIG. 8 is a flow diagram showing steps in measuring with a systemaccording to an embodiment;

FIG. 9 is a flow diagram showing steps in measuring with a systemaccording to an embodiment;

FIG. 10 is a flow diagram showing steps in measuring with a systemaccording to an embodiment;

FIG. 11 is a flow diagram showing steps in measuring with a systemaccording to an embodiment;

FIG. 12 is a flow diagram showing steps in measuring with a systemaccording to an embodiment;

FIG. 13 is a flow diagram showing steps in measuring with a systemaccording to an embodiment;

FIG. 14 is a flow diagram showing steps in measuring with a systemaccording to an embodiment; and

FIG. 15 is a flow diagram showing steps in measuring with a systemaccording to an embodiment.

DETAILED DESCRIPTION

An exemplary laser tracker 10 is illustrated in FIG. 1. An exemplarygimbaled beam-steering mechanism 12 of laser tracker 10 includes zenithcarriage 14 mounted on azimuth base 16 and rotated about azimuth axis20. Payload 15 is mounted on zenith carriage 14 and rotated about zenithaxis 18. Zenith mechanical rotation axis (not shown) and azimuthmechanical rotation axis (not shown) intersect orthogonally, internallyto tracker 10, at gimbal point 22, which is typically the origin fordistance measurements. Laser beam 46 virtually passes through gimbalpoint 22 and is pointed orthogonal to zenith axis 18. In other words,laser beam 46 is in a plane normal to zenith axis 18. Laser beam 46 ispointed in the desired direction by motors within the tracker (notshown) that rotate payload 15 about zenith axis 18 and azimuth axis 20.Zenith and azimuth angular encoders, internal to the tracker (notshown), are attached to zenith mechanical axis (not shown) and azimuthmechanical axis (not shown) and indicate, to relatively high accuracy,the angles of rotation. Laser beam 46 travels to external retroreflector26 such as the spherically mounted retroreflector (SMR) described above.By measuring the radial distance between gimbal point 22 andretroreflector 26 and the rotation angles about the zenith and azimuthaxes 18, 20, the position of retroreflector 26 is found within thespherical coordinate system of the tracker.

The laser tracker 10 is a device that has a device frame of reference30. The device frame of reference may have as its origin the gimbalpoint 22. The frame of reference may be fixed with respect to theazimuth base 16, which is typically stationary with respect to thesurroundings. The device frame of reference may be represented by avariety of coordinate systems. One type of coordinate system is aCartesian coordinate system having three perpendicular axes x, y, and z.Another type of coordinate system is a spherical coordinate system. Apoint 74 within a spherical coordinate 30 may be represented in aspherical coordinate system by one radial distance 73 (r), a first(zenith) angle 72 (θ), and a second (azimuth) angle 71 (φ). The angle θis obtained by using the projection of the point 74 onto the z axis. Theangle φ is obtained by using the projection of the point 74 onto the x-yplane. The laser tracker 10 inherently makes measurements in a sphericalcoordinate system, but a point measured in spherical coordinates may beeasily converted to Cartesian coordinates.

The target 26 may be in contact with an object under test 61. The objectunder test 61 has an object frame of reference 40. The object frame ofreference may be represented, for example, using Cartesian coordinatesx, y, and z. The x, y, and z axes of the object frame of reference 40move with the object 61 and are not necessarily parallel to thecorresponding device axes x, y, and z of the device frame of reference30. The target 26 may be placed in contact with the object surface 61 ata point 63. To find the three-dimensional (3D) coordinates of the point63, the tracker first determines the center of the target 26 using thedistance and two angles it has measured. It may also be used to accountfor a vector offset of the retroreflector reference point (e.g.,cube-corner vertex) with respect to the center of the spherical contactsurface of the target 26. To move from the center of the target to thesurface of the workpiece, the position of the center point is offset byan amount equal to the radius of the spherical target surface. In anembodiment, the direction of the offset is found by measuring severalpoints near to the contact point 63 to determine the surface normal atthe point 63.

Laser beam 46 may include one or more laser wavelengths. For the sake ofclarity and simplicity, a steering mechanism of the sort shown in FIG. 1is assumed in the following discussion. However, other types of steeringmechanisms are possible. For example, it would be possible to reflect alaser beam off a mirror rotated about the azimuth and zenith axes. Asanother example, it would be possible to steer the light beam by usingtwo steering mirrors driven by actuators such as galvanometer motors. Inthis latter case, the light beam could be steering without providingazimuth and zenith mechanical axes. The techniques described herein areapplicable, regardless of the type of steering mechanism.

In exemplary laser tracker 10, cameras 52 and light sources 54 arelocated on payload 15. Light sources 54 illuminate one or moreretroreflector targets 26. In an embodiment, light sources 54 are LEDselectrically driven to repetitively emit pulsed light. Each camera 52includes a photosensitive array and a lens placed in front of thephotosensitive array. The photosensitive array may be a CMOS or CCDarray, for example. In an embodiment, the lens has a relatively widefield of view, for example, 30 or 40 degrees. The purpose of the lens isto form an image on the photosensitive array of objects within the fieldof view of the lens. Usually at least one light source 54 is placed nearcamera 52 so that light from light source 54 is reflected off eachretroreflector target 26 onto camera 52. (To illuminate a retroreflectortarget in a way that can be seen on the camera 52, the light source 54must be near the camera; otherwise the reflected light will be reflectedat too large an angle and will miss the camera.) In this way,retroreflector images are readily distinguished from the background onthe photosensitive array as their image spots are brighter thanbackground objects and are pulsed. In an embodiment, there are twocameras 52 and two light sources 54 placed about the line of laser beam46. By using two cameras in this way, the principle of triangulation canbe used to find the three-dimensional coordinates of any SMR within thefield of view of the camera. In addition, the three-dimensionalcoordinates of an SMR can be monitored as the SMR is moved from point topoint. A use of two cameras for this purpose is described in U.S.Published Patent Application No. 2010/0128259 to Bridges, et al., thecontents of which are herein incorporated by reference.

Auxiliary unit 50 may be a part of laser tracker 10. The purpose ofauxiliary unit 50 is to supply electrical power to the laser trackerbody and in some cases to also supply computing and clocking capabilityto the system. It is possible to eliminate auxiliary unit 50 altogetherby moving the functionality of auxiliary unit 50 into the tracker body.In most cases, auxiliary unit 50 is attached to general purpose computer60. Application software loaded onto general purpose computer 60 mayprovide application capabilities such as reverse engineering. It is alsopossible to eliminate general purpose computer 60 by building itscomputing capability directly into laser tracker 10. In this case, auser interface, possibly providing keyboard and mouse functionality maybe built into laser tracker 10. The connection between auxiliary unit 50and computer 60 may be wireless or through a cable of electrical wires.Computer 60 may be connected to a network, and auxiliary unit 50 mayalso be connected to a network. Plural instruments, for example,multiple measurement instruments or actuators, may be connectedtogether, either through computer 60 or auxiliary unit 50. In anembodiment, auxiliary unit is omitted and connections are made directlybetween laser tracker 10 and computer 60.

In alternative embodiments of the present invention, the laser tracker10 may utilize both wide field of view (FOV) and narrow FOV cameras 52together on the laser tracker 10. Various exemplary methods of usingsuch cameras together are described hereinbelow.

In a first embodiment, one of the cameras 52 in FIG. 1 is a narrow FOVcamera and the other camera 52 is a wide FOV camera. With thisarrangement, the wide FOV camera 52 identifies the retroreflectivetargets 26 over a relatively wider angular extent. The laser tracker 10turns the light beam 46 in the direction of a particular selectedretroreflector target 26 until the retroreflector target 26 is withinthe FOV of the narrow FOV camera 52. The laser tracker 10 may then carryout a method described hereinafter for finding the location of aretroreflector target using images on the two cameras 52 mounted on thelaser tracker 10. This is done to find the best estimate for theposition of the retroreflector target 26.

In another embodiment illustrated in FIG. 2, both of the cameras 52 arewide FOV cameras. In addition, there is a narrow FOV camera 58 and anearby light source 56. The two wide FOV cameras 52 determine thethree-dimensional location of the retroreflector target 26 and turn thetracker light beam 46 toward the target 26. When the narrow FOV camera58 also sees the retroreflector target 26, the information provided byall three cameras 52, 58 is used to calculate the three-dimensionallocation of the retroreflector target 26.

In still another embodiment, the two wide FOV cameras 52 in FIG. 1 areused to locate the target and turn the laser beam toward it. Anorientation camera, similar to orientation camera 210 shown in FIGS. 2and 7 of the aforementioned U.S. Pat. No. 7,800,758 ('758) to Bridges,et al., which is incorporated herein by reference, views a small regionaround the illuminated retroreflector target 26. By observing theposition of the retroreflector 26 in the photosensitive array of theorientation camera 210, the laser tracker 10 can immediately direct thelaser beam 46 to the center of the retroreflector 26.

The method for finding the location of a retroreflector target usingimages on the two cameras 52 mounted on the front of the laser tracker10 of FIGS. 1 and 2 is now described.

Five frames of reference are associated with the laser tracker 10: apayload frame of reference that rotates with the payload 15; an azimuthframe of reference that rotates with the zenith carriage 14; atracker-world frame of reference that is fixed with respect to theazimuth base 16; and two camera frames of reference. The azimuth base 16is stationary with respect to its surroundings. The cameras 52 include alens system (not shown) and a photosensitive array (not shown).Representative illustrations of a camera containing a lens system and aphotosensitive array are given in FIGS. 4A-B.

In an embodiment, the payload frame of reference has an origin at thegimbal point 22, which lies at a point along the azimuth axis; a y axisparallel to the zenith direction; an x axis perpendicular to the y axisand approximately parallel to the laser beam; and a z axis perpendicularto the x and y axes. The cameras 52 are fixed with respect to thepayload frame of reference.

In an embodiment, the azimuth frame of reference has an origin at thegimbal point 22; a z axis along the azimuth direction; a y axis parallelto the zenith axis and perpendicular to the z axis; and an x axisperpendicular to the y and z axes.

In an embodiment, the tracker-world frame of reference has an origin atthe gimbal point 22; a z axis along the azimuth axis; a y axisperpendicular to the z axis and parallel to the zenith axis when theangle of the azimuth axis is set to zero degrees; and an x axisperpendicular to the y and z axes.

In an embodiment, a camera frame of reference has an x axis that is theoptical axis of the lens system within the camera. The y axis and z axisare perpendicular to the x axis and to each other and are aligned withthe rows and columns, respectively, of the pixels of the photosensitivearray within the camera 52.

In the laser tracker 10, a zenith angle and an azimuth angle, which areangles of rotation about the zenith and azimuth axes, respectively, aremeasured by the zenith encoder and azimuth encoder, respectively. Withknowledge of the zenith and azimuth angles and the equations of thecamera optical axes in the payload frame of reference, it is possible totransform any one of the five frames of reference—payload frame ofreference, azimuth frame of reference, tracker-world frame of reference,and two camera frames of reference—into any of the other frames ofreference. This is usually done using a transformation matrix, which isa 4×4 matrix including a 3×3 rotation matrix and a scaling componentthat enables translation. The use of transformation matrices is wellknown to those of ordinary skill in the art.

The cameras 52 and lights 54 are used to find the location of one ormore retroreflector targets 26 in the payload frame of reference or anyother frame of reference. Such targets can be automatically acquired, ifdesired, by the laser tracker 10.

The method for finding a retroreflective target in the payload frame ofreference will now be described. A first step in the method is to turnon the lights 54 to illuminate the retroreflectors 26 and form an imageon the cameras 52. In some cases, the illumination may be turned offbriefly and the difference taken between the illuminated andnon-illuminated scenes. In this way, background features can be removed,causing the retroreflector target to be revealed more clearly. A secondstep is use a processor (e.g., processor 50) to calculate a center pointfor each retroreflector spot on the photosensitive array of the camera52. The center point may, for example, be calculated as a centroid. Athird step is to establish a direction in the camera frame of referencefor each of the center points. With the simplest approximation, thedirection is found by drawing a line between the center point and theperspective center of the camera 52. A more sophisticated analysis mayconsider aberrations of the lens system in determining the direction. Afourth step is to convert into the payload frame of reference thecoordinates of the perspective center and the directions for each of thecenter points. A fifth step is to find a best estimate for the positionof the retroreflector target 26 in the payload frame of reference bysolving simultaneous equations, as explained hereinbelow.

For each retroreflector target 26, a center point will be formed on thephotosensitive arrays of each of the two cameras 52 and from thesecenter points a line indicating the direction from each of the camerasto the retroreflector target 26 will be constructed. In the ideal case,the two lines intersect in a point, but in general, the two lines willbe skew lines that do not exactly intersect. The best estimate of theintersection position for two skew lines is found by determining a linesegment of closest approach. The line segment of closest approach isperpendicular to each of the two skew lines and is shorter than anyother line segment perpendicular to the two skew lines. Ordinarily, thebest estimate of the position of the retroreflector target 26 is themidpoint of the line segment of closest approach.

FIG. 3 illustrates a two-dimensional representation of athree-dimensional vector diagram. Such a representation may be obtained,for example, in a top view wherein the tracker and the retroreflectortarget are viewed looking down from above. The point O is the origin ofthe payload frame of reference. The vectors P and R extend from theorigin of the laser tracker to a first camera and a second camera,respectively. The vector U represents the line passing through theperspective center of the first camera and having a direction calculatedaccording to the third step in the method above. The vector V representsthe line passing through the perspective center of the second camera andhaving a direction calculated according to the third step in the methodabove. The vector C represents the line segment that extends from afirst point on the vector U to a second point on the vector V. Thevector C is perpendicular to the vectors U and V.

One way to find the endpoints of the vector C is by using the equation

P+uU+cC=R+vV,  (1)

which contains the scalar quantities u, c, and v and the vectorquantities P, U, C, R, and V.

In addition, the vector C is subject to the constraint

C=U×V,  (2)

where x is the cross-product operator. Vector equation (1) can bewritten as a first equation in x, a second equation in y, and a thirdequation in z. The vector C can be written in terms of x, y, and zcomponents of U and V using well known cross product formulas. The x, y,and z components of C are substituted into the first, second, and thirdequations. The result is three equations in x, y, and z, where all ofthe vector quantities are known and only the three scalar quantities u,v, and c remain to be found. Since there are three equations and threeunknowns, the three values can be found.

The three dimensional endpoint coordinates Q₁ and Q₂ of the line segmentthat join the vectors U and V along the line of closest approach aregiven by

Q ₁ =P+uU,  (3)

Q ₂ =R+vV.  (4)

The best estimate Q of the intersection points of the two lines is givenby

Q=(Q ₁ +Q ₂)/2.  (5)

If desired, other mathematical methods can be used to find a bestestimate Q of the intersection points. For example, an optimizationprocedure may be used to find the values of Q₁ and Q₂.

The methods above are described with respect to a laser tracker 10having a beam of light 46 launched from a payload 15 rotating about azenith axis 18. However, other types of mechanical steering mechanismsare possible. For example, the payload 15 may be replaced by a steeringmirror. With this approach, a beam of light is directed upward from theazimuth base 16. The beam of light strikes the steering mirror andreflects out of the tracker enclosure. A motor attached to the zenithmechanical axis rotates the steering mirror to point the beam in thedesired direction. In this embodiment, the payload frame of reference isreplaced by the mirror frame of reference, but otherwise the analysis isthe same.

It would also be possible to use one or more cameras not attached to thepayload of the laser tracker. Such cameras might be attached to theazimuth carriage 14 or they might be mounted separate from the lasertracker altogether. The method for finding the relationship between theframes of reference of the cameras and the laser tracker would be foundin a manner similar to that described above: some number of points wouldbe measured by the cameras and by the laser tracker and the measurementresults would be used to establish appropriate transformation matrices.

Referring again to FIG. 2, since in most cases the narrow FOV camera 58will have a smaller angular range covered by each pixel, it isadvantageous to weight the reading of the narrow FOV camera 58 moreheavily. A simple way of doing this is to revise Eq. (5) above. Forexample, if the FOV of the narrow FOV camera 58 is one quarter that ofthe wide FOV camera 58, a reasonable equation to use in place of Eq. (5)above may be:

Q=0.2Q ₁+0.8Q ₂  (6)

Another mathematical method that may be used is a least squaresoptimization procedure to find the best estimate for the retroreflectortarget 26, but to weight the readings of the narrow FOV camera 58 moreheavily than the readings of the wide FOV camera 52.

Referring to FIGS. 4A and 4B, a locator camera 400 allows the lasertracker 10 to quickly determine the approximate location of multipleretroreflectors within a relatively wide field of view of the lasertracker 10. A plurality of identical light sources 401 is provided in aring surrounding a lens 402. Alternatively, fewer lights or even asingle light may be used. The individual light sources emit overlappingcones of essentially incoherent light 440 that collectively constitute acone of light. Each of the retroreflectors reflects some of the lightfrom the cone of light back to the locator camera 400 as the bundles oflight. One of the bundles of light 457 is shown in FIG. 4B. Lens 402focuses the bundle 457 down to a spot on the surface of photosensitivearray 404. The photosensitive array 404 is separated from the frontprincipal plane 403 of lens 402 by the focal length f of the lens.

Electrical wires 441 provide power from a power source (e.g., auxiliaryunit 50) within the laser tracker 10 to the emitters 401 and thephotosensitive array 404. Electrical wires 441 also transmit the pixeldata from photosensitive array 404 to general purpose computer 60, forexample, for analysis. The computer 60 analyzes the pattern of light onphotosensitive array 404 to determine the location of a central point452 on photosensitive array 404. The computer 60 also performs thisanalysis of the pattern formed by the other bundles of light returned bythe retroreflectors. In other words, the reflected light bundles arefocused by lens 402 into patterns on photosensitive array 404. Thecomputer 60 analyzes these patterns to determine the central point ofeach pattern. From the location of the central points, the approximateangular direction to each of the retroreflectors can be determined.

Suppose that the retroreflector of interest is a particularretroreflector among the multiple retroreflectors. If the objective isto acquire the target and measure the target positions with the lasertracker, then the following procedure may carried out. Motors areactivated to turn the payload until the laser beam points in theapproximate direction of a particular retroreflector. If the estimate ofthe target position is good enough, the light beam directly locks ontothe target and begins tracking of the target. If the estimate of thetarget position is not good enough, one possibility is to initiate asearch in which the direction of the laser beam is changed in asystematic fashion. For example, the laser beam might be steered along aspiral pattern. When the laser beam intersects the target, a positiondetector within the laser tracker senses the reflected light. Thesignals from position detector provide enough information to enablemotors to point the payload directly to the center of the particularretroreflector. Another possibility is for the operator to directly grabthe mechanical mechanism of the laser tracker, for example, the payload,and to manually direct the light beam toward the retroreflector ofinterest. In one embodiment, if the operator directs the light beamclose enough to the center of the retroreflector, an LED begins to flashon the front of the tracker. If the light beam is closer still, thelight beam will lock onto the retroreflector target. If the light beamis not quite close enough to the center of the retroreflector to lockonto the target, a quick search procedure may be carried out to locatethe retroreflector target.

In the case that two or more locator cameras 52 are on the laser tracker10, it is usually possible to directly establish, by means of the stereocamera calculation described hereinabove, a one-to-one correspondencebetween the retroreflector targets 26 and the target centers appearingon the photosensitive arrays of the cameras 52. Similarly, if a singlecamera 52 is located within the laser tracker in such a way that thelight reflected by the targets 26 travels to the camera on an opticalaxis of the laser tracker, then a parallax between the camera and thecamera is eliminated, and it is usually possible to establish aone-to-one correspondence between the retroreflector targets and thetarget centers appearing on the photosensitive array of the camera. If asingle camera is used, alternative methods may be used to establish aone-to-one correspondence between the target centers and theretroreflector targets. One method involves turning the azimuth axis todifferent angles and observing the change in position on thephotosensitive array of the single camera 52. As the azimuth angle ischanged, the positions of the centers on the photosensitive array willchange by an amount that depends on the distance from the laser tracker10 to the retroreflector 26. For a given change in azimuth angle, as thedistance to the retroreflector increases, the change in between the twocenters on the photosensitive array decreases. A similar procedure canbe carried out by changing the zenith angle, rather than the azimuthangle, of the of the laser tracker. A more detailed description of thisprocedure is described in reference to FIG. 18 in U.S. PatentApplication No. 2011/0260033 ('033), incorporated by reference herein.

In some cases, the one or more cameras on the laser tracker are accurateenough to direct the light beam from the laser tracker close enough tothe center of a retroreflector target so that the light beam reflectedback into the laser tracker is picked up by the position detector,thereby causing the laser beam to begin tracking the target. In suchcases, the software that controls the laser tracker may automaticallydirect the light beam from the tracker to each of the targets so thatthe relatively high accuracies of the laser tracker distance meter andangular encoders are transferred to the three dimensional coordinatevalues. In other cases, the one or more cameras on the laser tracker maynot be accurate enough to immediately direct the light beam from thelaser tracker close enough to the center of the retroreflector target toenable the position detector to immediately detect the light beam andbegin tracking. In this case, the light beam from the laser tracker maybe aimed at a target and the beam directed in a search pattern to locatethe target, as explained hereinabove. By repeating this procedure foreach of the targets within the measurement volume, relatively accuratethree dimensional coordinates can be obtained for each of the targetpoints. Relatively accurate three dimensional coordinates for the targetpoints are important because they enable the software that controls thelaser tracker to efficiently carry out automatic measurements of thetarget points without performing interim target searches.

As suggested by the discussion hereinabove, some aspects of thisinvention require the obtaining of a one-to-one correspondence betweentarget points viewed by the one or more cameras on the laser tracker anda list of three dimensional coordinates of retroreflector target points.Some methods for obtaining a list of three dimensional coordinates ofthe target points are described hereinbelow. The list may, in somecases, have nominal three dimensional coordinates that differ by arelatively large amount from the actual three dimensional coordinates.In other cases, the list may have relatively accurate three dimensionalcoordinates.

In an embodiment, a list of three dimensional coordinates between thelaser tracker and the target points on an object under test is obtainedfrom a CAD model describing the positions of the targets on the object.

In another embodiment, the one-to-one correspondence between the targetpoints and the list of three dimensional coordinates is obtained byperforming three dimensional measurements on each of the points observedby the camera. Such three dimensional measurements may have been carriedout prior to the current measurement session.

In some cases, the images of the target points on the one or morecameras may be too closely spaced to immediately determine theone-to-one correspondence between the target points and the spots on thecamera images. In this case, the points may be measured with the lasertracker using the methods described hereinabove. For example, the lasertracker may direct the light beam toward the target. The laser trackermay then measure the target position directly or with the assistance ofa search procedure, if necessary.

An important aspect of this invention is the establishing of arelationship between the frame of reference of the laser tracker and theframe of reference of the object under test. Another way of expressingthe same idea is to say that it is important to have a method fortransforming the laser tracker frame of reference into theobject-under-test frame of reference or vice versa.

Three methods are taught herein for the establishing of thisrelationship. In a first method, at least three retroreflector targetpoints are measured by the laser tracker. In a second method, at leasttwo target points are measured by the laser tracker and in addition atleast two angles of tilt are measured by inclinometers disposed on eachof the laser tracker and the object under test. In a third method, asingle six degree-of-freedom (DOF) camera is measured by a laser trackerhaving six DOF measurement capability. By combining the informationobtained from any of the three methods, it is possible to put the lasertracker within the frame of reference of the object under test.Equivalently, it is possible to put the object under test within thelaser tracker frame of reference.

A brief explanation will now be given on the method for putting theobject under test into the tracker frame of reference based on theobtaining of the measured information described in the precedingparagraph. For the case in which the laser tracker measures threeretroreflector target points, a local coordinate system for the objectunder test may be established by allowing one of the three measuredpoints to be an origin point in the local frame of reference of theobject under test, a second of the measured points to establish the xaxis, and the third of the measured points to establish a component inthe y direction. The y axis is taken to pass through the origin and tobe perpendicular to the x axis. The z axis is taken to pass through theorigin and to be perpendicular the x axis and the y axis and to have adirection according to the right-hand rule, which is known to those ofordinary skill in the art. The object under test may have its ownreference coordinate system established by a CAD drawing. For example,the CAD drawing may have datums that establish an origin, x axis, yaxis, and z axis. To put the CAD drawing within the frame of referenceof the laser tracker, or equivalently to put the laser tracker withinthe frame of reference of the CAD drawing, usually three transformationmatrices are obtained. Transformation matrices are usually 4×4 matricesthat include a 3×3 rotation matrix and a scaling component that accountsfor translations of the frames of reference relative to the other framesof reference. In the situation described hereinabove, the threetransformation matrices are multiplied together in a particular order toobtain an overall transformation matrix to transform measured values orCAD values into the desired frame of reference. The use oftransformation matrices is well known to one of ordinary skill in theart and will not be described further here.

For the case in which the laser tracker measures the three dimensionalcoordinates of at least two retroreflector target point in addition toangles of tilt of the laser tracker and the object under test, a localcoordinate system for the object under test may be established byallowing a first retroreflector target point to be the local origin ofthe object under test and the direction from the first target point tothe second target point to establish a local x axis for the object undertest. If an inclinometer located on the laser tracker and the objectunder test each measures two perpendicular tilt angles and to thegravity vector, then it is possible to rotate the object under test toalign the two gravity vectors, again using rotation methods that arewell known to one of ordinary skill in the art. The ambiguity in therotation angle about the gravity vector can be removed since there isonly possible rotation about the gravity vector that provides thatproper correspondence between the local x axis of the object under testand the x axis as defined by the CAD model. This method will work aslong as the three dimensional coordinates of the two retroreflectortarget points, as measured by the laser tracker, do not form a line thatcoincides with the gravity vector.

Another way of viewing the transformation between frames of reference isto consider the number of degrees of freedom provided by the measuredvalues. For example, when the laser tracker measures a firstretroreflector target point, it is said to have constrained the possiblemovement of the object under test by three degrees of freedom because afirst, second, and third degree of freedom corresponding to x, y, and zcoordinates have been established for a point on the object under test.Physically, this constraint fixes the location of the measured point inspace but allows the object under test to rotate in any orientationabout this point. When the laser tracker measures the secondretroreflector target point, it is said to have constrained the possiblemovement of the object under test by an additional two degrees offreedom because the object under test no longer has the ability torotate in any of three orientational angles but instead is constrainedto rotate about the line connecting the first and second retroreflectortarget points. Hence the three degrees of orientational freedom havebeen reduced to one orientational degree of freedom. The first measuredpoint constrained three translational degrees of freedom, and the secondmeasured point constrained two orientational degrees of freedom for atotal constraint of five degrees of freedom. Since there is oneunconstrained degree of freedom in this case, the total of theconstrained and unconstrained degrees of freedom is six.

For the case in which inclinometers on the laser tracker and the objectunder test each measure two angles of tilt relative to the gravityvector and the laser tracker measures the three dimensional coordinatesof just one target point, there is not enough information to fullyconstrain the object under test. The two inclinometers constrain twoangles but provide no information on rotation of the object under testabout rotation about the gravity vector. In other words, the twoinclinometers constrain two degrees of freedom. The three dimensionalcoordinates of the single target measured by the laser tracker providesconstraint of three degrees of freedom, for a total constraint of fivedegrees of freedom. Since six degrees of freedom are needed for completeconstraint, the measured values do not provide complete constraint, andthe object is free to move around the gravity vector.

For the case in which inclinometers on the laser tracker and the objectunder test each measure two angles of tilt relative to the gravityvector and the laser tracker measures the three dimensional coordinatesof two target points, there is enough information to fully constrain theobject under test as long as the two target points do not establish aline along the direction of the gravity vector. By performing thismeasurement, the object under test is said to be constrained in sixdegrees of freedom as long as the two target points do not lie along thedirection of the gravity vector.

For the case in which the two vectors lie along the gravity vector, theobject under test is said to be constrained by five degrees of freedomsince there is not enough information to determine the orientation ofthe object under test about the gravity vector. Note that the number ofdegrees of freedom cannot be determined by simply adding the number ofdegrees of freedom that would be obtained by individual measurements.For example, measurement of a single point constrains three degrees offreedom, but the measurement of two points constrains five degrees offreedom, not six degrees of freedom. Also notice that the two angulardegrees of freedom provided by the inclinometers on the laser trackerand the object under test do not add to the five degrees of freedomobtained by the laser tracker measurement of the two retroreflectortarget points to obtain six or seven degrees of freedom. This is becausethe two degrees of freedom provided by the inclinometers do notcorrespond to a basis set that is independent of the basis set of thetwo target points measured by the laser tracker. In other words,complete constraint of a single rigid body requires constraint of threetranslational degrees of freedom (e.g., x, y, z) and three orientationaldegrees of freedom (e.g., pitch, roll, and yaw angles). In the caseconsidered above, there is no constraint for rotation about the gravityvector (often called the yaw angle). In this application, the termdegrees of freedom should be understood to mean independent degrees offreedom.

It should be understood that the targets viewed by the cameras on thelaser tracker may be in a region beyond the field of view (FOV) of thecameras by rotating the azimuth and zenith axes of the laser tracker.For example, the FOV of one of the cameras on the laser tracker may be30 degrees in the azimuth direction. However, the azimuth axis of thetracker may be rotated by 360 degrees, thus increasing the effective FOVof the camera to 360 degrees.

Embodiments of the present invention allow an operator with limitedtraining on the measurement system (e.g., laser tracker, target tooling,SMRs or other laser tracker targets, computer system, measurement systemsoftware and optionally a remote control or handheld device connected tothe measurement software) optionally to follow a series of prompts andinstructions via a computer (e.g., the general purpose computer 60) toset up the laser tracker, optionally to place the SMRs in the requiredtooling on the part to be measured, and optionally to define the area ofinterest to be measured. The measurement system may then automaticallymeasure the target points and produce the results.

An embodiment of the present invention that helps enable simpler andfaster measurements for the operator is a method in which the lasertracker points the light beam at a desired measurement location on theobject to prompt the operator to place an SMR at the desired location.For example, the operator might be prompted to place a retroreflectortarget in a magnetic nest on an object under test. As another example, aretroreflector may be located in the wrong position, and the operatormay be prompted by the light beam from the laser tracker to move themisplaced target to the correct location. The prompting might do this,for example, by moving the light beam sequentially from a first positioncontaining the misplaced target to a second position where the target isto be placed.

The guidance given by the light beam from the laser tracker may alsohave an advantage during a setup phase in which the operator places SMRsin specified locations while the laser tracker measures the threedimensional coordinates of the target positions. This advantage is seenwhen the nominal dimensions given on a CAD model do not correspond tothe actual dimensions of an object under test. If the accurate threedimensional locations of the target points are determined during setup,measurement time and errors occurring later in the process may bedecreased.

The directing of the actions of the operator by pointing of the lightbeam can help eliminate errors. For example, a test plan within softwarefor a laser tracker test may indicate that the operator is to measurepoints in a particular order. The results of such measurements may besaved and used to obtain a desired relationship—for example, arelationship between two frames of reference, a length between twolines, or the angle between two planes. If the operator has measured theinitial points in the wrong order or has measured the wrong points, thenthe software may fail to solve for the desired values or get the wronganswers.

In the cases described thus far, the operator is directed to place aretroreflector target in a fixed location, which might be a magneticnest or a tooling hole, for example. However, there is another importantcase in which the operator measures a surface profile. Such a surfaceprofile might be measured to determine the flatness of a surface or thediameter of a sphere, for example, or two surfaces might be measured todetermine the angle between the surfaces. As another example, anoperator might measure a portion of a tool being built for use inassembling automobiles or airplanes. The laser tracker might be used tomeasure the surface profile to see whether the profile is within thedesign tolerances. If not, the operator might be directed to modify thetool in an appropriate manner—perhaps by abrading material from aregion, for example. In all of these cases in which the SMR is used tomeasure the profile of a surface, the software that controls the lasertracker may greatly simplify and speed the procedure by the operator byindicating the region that is to be scanned. It may do this by causingthe laser tracker to direct the light beam to delimit the areas theoperator is to scan. Alternatively, it might trace the actual path theoperator is to follow during the scan.

The laser tracker may also be used to assist in the assembly of complexstructures. For example, it may be necessary to affix a number ofcomponents to the cockpit of an aircraft. In many cases, a costeffective way to do this is to point a light beam to instruct theassembler to drill holes or perform other operations at the appropriatelocations. After the components have been attached, the operator may beinstructed to scan the profile of the installed items to confirm thatthe installation has been made properly. To facilitate this measurement,one or more cameras may be used to identify retroreflectors on theobject under assembly. These retroreflectors would be used to move thelaser tracker into the frame of reference of the object under assembly,which would then enable the laser tracker to direct the activities ofthe assembler using the light beam from the tracker.

The one or more cameras on the laser tracker have the ability to measureall of the retroreflector targets within a large effective FOV byrotating the azimuth and zenith axes, as explained hereinabove. If theonly targets accessible to the laser tracker are those on the objectunder test, the laser tracker can automatically determine, by viewingthe retroreflector targets, the region of space to be measured. On theother hand, if targets occupy several objects, not all of interest tothe current measurement, it may in some cases be necessary for theoperator to indicate the region that is to be measured. In anembodiment, the operator may indicate the region to be measured by usinga retroreflector to delimit the region of interest. The operator may dothis, for example, by making four consecutive movements of theretroreflector target to indicate the upper, lower, left, and rightextent of the region. In another embodiment, the operator may manuallymove the payload (or equivalent structure) of the laser tracker to pointthe light beam in the upper, lower, left, and right edges of the regionof interest. The operator may be instructed to carry out these movementsby software that controls the laser tracker, or the operator may givegestures to give this information without being directed to do so by thecomputer program. Such gestures may include, for example, movement of aretroreflector target in predetermined patterns within specified timeintervals. As another example, the operator may indicate the desire todelimit a region by grabbing the payload and moving the light beam fromthe laser tracker directly downward. The operator could follow thisinitial movement by moving the payload to delimit the upper, lower,left, and right edges of the desired measurement region. In other cases,it may be possible for the software that controls the laser tracker toperform a target matching procedure in which the software identifies acollection of retroreflector targets in correspondence to a CAD model orto a list of three dimensional coordinates of targets.

In discussions above, the benefits of having the laser tracker using thelight beam to assist the operator in performing measurements has beenemphasized. Now the benefits of completely automating a measurement areconsidered. One potential benefit is that, because of the speed withwhich a fully automated measurement can be performed, additional targetsmay be added to the object under test without increasing the test time.By providing more points in each set of data, the software may morequickly determine the desired geometrical characteristics of the objectunder test with fewer potential errors. Also, by measuring sets ofpoints without having the user manually move the SMR, the chance ofhaving the object get shifted during the measurement session arereduced. This in turn reduces the chance of measurement errors.

A potential advantage of a fully automated measurement is that the orderin which measurements are made can be optimized. In the case in whichthere are a large number of target positions on an object under test, anoperator may measure the target positions according to relativeproximity of the points since this is the fastest procedure for manualmeasurement. In a fully automated procedure, on the other hands,measurements may be performed in an order which produces the mostaccurate and robust measurement results. For example, two points on adatum line may be on opposite sides of a large object under test. Anautomated test procedure can measure these widely separated datum pointsone after the other, thereby avoiding drift and getting the mostaccurate measurement results.

Another potential advantage of automatic measurement is the possibilityof automatic refit. It is often desirable to periodically measure thecharacteristics of tools used in the manufacture of products. Suchperiodic measurements help ensure that the tool has not gotten bent,that the targets have not moved, and so forth. If an object under testhas gotten bumped, then during a periodic measurement this will benoticed by the software that controls the laser tracker. The softwaremay in response invoke an automatic refit procedure in which the newlocation of the bumped target is re-established. The automatic refitprocedure may also reduce the requirement for rigid mounting to hold theobject rigidly on the tool. Reduced rigidity requirements results inreduced costs for building and operating a very accurate, repeatabletool.

Another example of automatic refit is for the case in which the objectunder test is on an assembly line. Such an object will probably not bein exactly the same location after it has completed a circuit and hasreturned to the laser tracker for an inspection. The laser tracker canmeasure the reference points to re-establish the relationship the frameof reference of the laser tracker and the frame of reference of theobject under test.

One capability made possible by the automated measurements describedabove is the setting of a desired accuracy value, possibly by the user,to drive specific operations and set thresholds for alerts and alarms.For example, the value set for desired accuracy can drive: (1) thefrequency and tolerance on stability checks; (2) self-compensationversus full pointing comp requirement; (3) the frequency and toleranceof self-compensation; (4) the threshold for number of measurementsamples per point measured; (5) ambient temperature change limits beforecompensation checks; (6) tolerance for acceptable results of alignmentsand position moves; and (7) the frequency and tolerance of drift checks.

Alternatively, each of these values can be set individually. A matrix ofvalues can be set based on different applications and operatingconditions and these could be saved and recalled as measurementprofiles.

An example is now considered in which a setup procedure includescooperation by the operator rather than complete automation. For thedesired measurement locations, the laser tracker 10 aims at a desiredposition on the object to place an SMR. In a first embodiment, theoperator holds the SMR in hand while placing the SMR in the light beam,thereby enabling the beam to lock onto the SMR. After the SMR is putonto the object (e.g., on a magnetic nest), the laser tracker measuresthe three dimensional coordinates and moves the light beam to the nexttarget position. In a second embodiment, the operator places theretroreflector immediately on the object, which might be on a magneticnest, for example. If the light beam does not immediately lock onto theretroreflector, the operator gives a signal by, for example, passing ahand in front of the retroreflector target, thereby causing the targetto flash in the view of the camera. The tracker searches for the SMR andquickly measures the SMR location. The tracker then advances to the nextnominal point to guides the operator as to where to place the target onthe object. A third embodiment is like the second embodiment except thatthe laser tracker does not do a search if the target is not immediatelyfound. Instead, when the operator passes a hand in front of theretroreflector target, the laser tracker directs the light beam to thenext target location. During an initial setup, it may be acceptable tomake all of the measurements relatively quickly by limiting eachmeasurement time to about 0.1 second, for example.

A large number of retroreflector targets, which may exceed 100, may beused to measure points on a tool. In some instances, the operator maywish to put on only a portion of the retroreflectors at a time (e.g., 25retroreflectors at time) to save money on the purchase ofretroreflectors. A measurement cycle is defined as the cycle over whichthe available retroreflector targets (e.g., 25 targets) are located onthe tool and measurements are performed by the laser tracker.

If the SMRs are not already affixed to the object under test, theoperator places the SMRs on the object either manually or by using theguidance provided by the laser tracker 10. The tracker may then conducta stability and reference system check. The stability check may beconducted by measuring one or more points. In an embodiment, the trackermeasures two or more points at the extreme boundaries of the measurementvolume along with one point nearest the center of the volume. The lasertracker 10 automatically takes a series of points with shorter andprogressively longer duration (more samples) to determine the optimalnumber of samples to achieve the desired accuracy (the operator setsthis number in the system). The systems setting for samples per pointare set to this value. The system will have the option to recheck thestability after a certain period of time, a number of points measured orat the beginning and/or end of each cycle. After the reference points(minimum of three) have been measured the first time, they can bere-measured at the end of the cycle to check movement or at thebeginning of each cycle to re-orient the laser tracker to the part tocorrect for any movement of the object that may have been introduced bythe operator while moving the SMRs. A simpler and faster method forchecking possible movement is to place a single point on the object anda second point somewhere else; e.g., on the floor. These positions willhave SMRs in them all the time and the measurement system canperiodically check them throughout the measurement session. One way isto check at specific intervals during the measurement session inaddition to the beginning and end of each cycle. A minimalimplementation would to measure these drift points at the beginning andend of each measurement session.

The measurement system automatically measures all of the required pointsper the system settings. The laser tracker's user lights can flash apattern of LEDs after each point is measured to alert the operator as toa passing or failing point. If a point fails, the operator can pause theautomatic measurements by waving a hand in front of any target in thetracker's FOV. The camera system will register the break in the flashingof a single target produced in response to the flashing light source 54and pause the measurements. The operator can hold a hand in front of theout-of-tolerance point so that it can be adjusted. The laser trackerthen aims at the desired point. A digital readout guides the operator toadjust that portion of the tool that is out of tolerance. When theadjustment is complete, the operator may give another gesture (e.g.,moving a hand in front of the SMR) to command the laser tracker tore-measure the point and continue measuring the rest of the points. Byeither flagging the SMR or physically moving the azimuth or zenith axisof the systems, it will be possible to execute the full measurementprocess so that the operator does not need to use a remote control,mouse or keyboard.

Referring to FIGS. 5 and 6, there illustrated are perspective views ofthe laser tracker 10 of FIG. 1 or 2 in first and second orientations,respectively, with respect to an object 500 to be measured with thelaser tracker 10 automatically taking measurements of various targetpoints 26 (e.g., SMRs 26) on the object 500. The object 500 can be anytype of relatively large object, such as a carriage that is part of anassembly line for automobiles. However, this is purely exemplary; theobject 500 can be any type of tooling or finished product. As discussedhereinabove, the object 500 has multiple target points 26, for exampleSMRs 26, placed on the object 500 at various locations in accordancewith embodiments of the present invention. SMRs may also be placed onthe assembly being held by the object 500.

FIG. 5A illustrates a number of SMRs 26 at various locations on theobject 500. Also shown is the laser tracker 10 having its laser beam 46pointed at a number of these SMRs 26. In addition, a cone 510illustrated that represents the field of view of the one or more cameras52, 58 of the laser tracker 10 as the camera(s) are viewing a portion ofthe object 500.

FIG. 5B is similar to FIG. 5A but now the laser tracker 10 is turnedwith respect to the object 500 and also some of the SMRs 26 on theobject 500 at specific locations in FIG. 5A have been moved to otherlocations on the object 500 in FIG. 5B. Also, the cone of the field ofview of the camera(s) 52, 58 is in a different orientation with respectto the object 500. This enables the camera(s) 52, 58 to capture otheradditional target points 26 on the object 500. The movement of thetarget to two different positions may be achieved in either of two ways.In an assembly line, the carriage may move a short amount to allow thechange in laser tracker perspective as seen in FIGS. 5 and 6. For astationary tool, the laser tracker may be moved to enable measurement ofpoints that might be otherwise hidden from view.

Due to the size of the object 500 being measured and the accuracies thatmay be desired, the ambient temperature of the object 500 could become asource of measurement error if not addressed. For example, metalstructures may expand as they get warmer. Also, the nominal values ofthe object (e.g., the CAD file) are often set at the temperature of acontrolled room in the range of 20 degrees C. or 68 degrees F. If theobject being measured is warmer than this it will be physically larger.It is common practice to adjust for this difference by applying a scalefactor to the measurement job and adjusting the measurement data back tothe design temperature by knowing the part material and temperature orby measuring reference points and applying a scale factor whentransforming the job.

In an automated measurement session, where reference points 26 are beingused and measured, the operator may indicate by a setting in thesoftware to always apply a scale factor when transforming the job. Theproblem with this practice is that if the geometry of the object ischanged, bent, etc., the automatic scale method will reduce this errorby changing the scale of the job. A second method may be to use amaterial sensor placed on the object and have the operator enter thecoefficient of expansion or material type and the system can determinescale based on these inputs. However, a preferred method by which anautomated system may operate is to compare the two methods and alert theoperator if any variation exceeds the desired system accuracy. Theoperator would place one or more material sensors on the object. Thesystem can check the ambient temperature via an internal tracker sensoror an external sensor. If the difference is great enough to cause thepart to expand or contract during the measurement session, the systemwould alert the operator to allow the object to soak in the environmentand delay the measurement until the object temperature stabilizes. Themeasurement job may include the material type and/or the coefficient ofexpansion of the material. The system measures the reference points onthe object and compares their values to nominal or desired values.

During the transformation process the system calculates the scale factorbased on the transformation of measured to nominal and calculates scalebased on the material type and material temperature sensor. If there isan unacceptable difference between the two scale calculations theoperator will be alerted and the measurement session is halted. Thisdifference may indicate that one of the following conditions hashappened and the system may not be able to measure the job as expected;(1) the material temperature sensor(s) and/or the air temperaturesensor(s) may be defective and producing the wrong values; (2) or themore common cause may be that the object is geometrically deformed tothe point where the reference points 26 are no longer at the designlocation on the object. This is relatively difficult to detect incurrent measurement sessions as the automatic scaling tends to hidethese errors and introduce uncertainties or errors across the entirejob. If the reference points have errors, traditionally the entire jobwill be shifted slightly off nominal and this can cause some points tofail incorrectly. If the highest accuracy is desired, additional checkscan be performed by the system during the measurement session tominimize expansion or contraction of the part.

The relatively most automatic system may be to use the stereo cameras 52on the laser tracker 10 to determine depth and position to estimate thelocation of the SMRs 26. In an embodiment, the operator places the SMRs26 on the object 500 and manually aims them in the direction of thelaser tracker 10. The operator indicates the desired measurement volumeby manually moving the azimuth and zenith axes of the tracker 10 to therelatively extreme points of the measurement volume as prompted by thesoftware. The software prompts the operator to move the tracker head andlaser beam 46 to the furthest right point; the operator then moves thetracker head. When the movement is stable for a specified amount of time(e.g., two seconds), the system records the location. The softwareprompts the user to move the tracker head to the furthest left, top andbottom of the intended volume.

If the indicated volume exceeds the range of the widest field of view ofthe camera system 52 on the tracker 10, the tracker then executes aprogrammed sweep/survey of the entire volume looking for SMRs 26 ortargets. This programmed sweep/survey will be repeated as requiredthroughout the measurement session to monitor the status of the SMRs orlook for user input to the system. Using the stereo cameras 52 the lasertracker 10 estimates the XYZ location for every point within themeasurement volume. The measurement system software calculates a firstapproximation on the transformation between the tracker and the set ofpoints. The tracker then aims at the desired points. If any points arenot visible from the measurement set, the tracker 10 flashes an errorwith the LEDs on the front of the tracker (not shown) and then aims atthe location where the target 26 is missing, miss-aimed or obscured byanother object. The tracker can move in a fixed pattern to make thelocation more visible for the operator. Once the point is corrected, theoperator can flag the SMR 26 and the system will know to measure thelocation and proceed with the process. Again automatically, the tracker10 aims at and uses the camera system 52 or traditional search system tolock onto and measure each target 26.

As stated in the previous paragraph, when pointing a light beam toward atarget location, it can sometimes be a good idea to move the light beamin a pattern rather than pointing it at a fixed angle. Consider, forexample, the case in which a magnetic nest is located off the top of anobject under test. In this instance, a light beam pointed directlytoward the target location (i.e., the center of the retroreflectortarget when placed in the magnetic nest) may be invisible to theoperator since it may pass by the object without striking anything inits path. By moving the light beam in a pattern, the desired position ofthe SMR can be made visible.

If the laser tracker 10 is equipped with one or more wide field of view(WFOV) cameras and one or more narrow field of view (NFOV) cameras, thesystem can locate the general position of the SMR 26 with the WFOVcamera and aim at the point 26. If the laser beam 46 does not hit thecenter of the target 26 close enough to enable the tracking system tolock onto the target, one or more of the following processes can beexecuted. (1) The tracker can reevaluate the position from the WFOVcamera(s) and aim again at the stationary point. (2) The tracker canswitch to the NFOV camera(s) and recalculate the optical center of thetarget and aim at this calculated center and attempt to acquire thetarget with the tracking system. (3) If the tracker is equipped with anoptical zoom function on the NFOV camera(s) and the NFOV camera(s)cannot see the target after changing from the WFOV cameras (the WFOVposition calculation caused the tracker to aim at a position that hasenough error that the NFOV camera(s) cannot see the SMR), the NFOVcamera can zoom out to the point where the target is visible and thencalculate the optical center and properly aim the tracker.

Any of these processes can be repeated until the target is re-acquired,the advantage is that using the combination of the WFOV and NFOV cameras(referred to as the camera system herein) can be faster than thetraditional aim and search method using the laser beam and positionsensor.

In other embodiments of the present invention, another measurementprocedure may be to compare, under the direction of software,measurement results to allowable tolerances. The laser tracker 10 maycompare the nominal (CAD model) dimensions between target points on atool and the dimensions as measured by the laser tracker. If the errorbetween a nominal dimension and a measured dimension exceeds a tolerancevalue, the tracker may take action. This action may be as simple asre-measuring the points or measuring the points for a longer time. Thetracker may also perform a two-face measurement to ensure that theproblem is not with tracker accuracy. In the alternative, the actiontaken by the tracker may be to send the operator an error message, sounda beep, flash a light, or even shut down the production line until theoperator checks the stability, makes an adjustment, or replaces adefective target, for example.

Embodiments of the two-face test are described in U.S. Pat. No.7,327,446 ('446) to Cramer et al., which is incorporated by reference inits entirety. The tracker 10 makes a two-face measurement of one or moretarget points 26. If the two-face error obtained exceeds the specifiedvalue (for example, as given in the manufacturer's data sheet), afurther step might be for the tracker to carry out a compensationprocedure to improve tracker performance. There are two types ofcompensation procedures that are most commonly carried out (althoughother procedures are possible). These two procedures are theself-compensation procedure described in the '446 patent and thepointing compensation procedure. The pointing compensation procedureincludes making a number of two-face measurements by pointing at targetsthat may be mounted on the floor, on pedestals, or on an object. Aftercollecting the data from the pointing compensation, the trackerautomatically corrects its internal parameters, thereby improving itsmeasurement accuracy.

Another measurement procedure might be to check for stability ofmeasurements over time. For example, the tracker may measure a targetpoint on a floor and another target point on the tool. If the relativepositions of these two target points change over the course of ameasurement, the tracker may send the operator a warning. Similarly, thetracker may measure the distance between three points on a tool, andthen come back at the end of the measurement and measure these threepoints again. If the relative positions of these points change, thevalidity of the entire measurement is called into questions, andadditional measurements may be required.

Although the discussion has mostly treated the case in which the one ormore cameras are located on the payload of the laser tracker, it willunderstood by one of ordinary skill in the art that such cameras may belocated internally to the laser tracker (e.g., coaxial with the opticalaxis of the laser tracker), located on the azimuth carriage 14 of thelaser tracker 10, or entirely off the laser tracker.

FIG. 6 is a block diagram depicting a dimensional measurementelectronics processing system 1500 that includes a laser trackerelectronics processing system 1510, peripheral elements 1582, 1584,1586, computer 1590, and other networked components 1600, representedhere as a cloud. Exemplary laser tracker electronics processing system1510 includes a master processor 1520, payload functions electronics1530, azimuth encoder electronics 1540, zenith encoder electronics 1550,display and user interface (UI) electronics 1560, removable storagehardware 1565, radio frequency identification (RFID) electronics, and anantenna 1572. The payload functions electronics 1530 includes a numberof subfunctions including the six-DOF electronics 1531, the cameraelectronics 1532, the ADM electronics 1533, the position detector (PSD)electronics 1534, and the level electronics 1535. Most of thesubfunctions have at least one processor unit, which might be a digitalsignal processor (DSP) or field programmable gate array (FPGA), forexample. The electronics units 1530, 1540, and 1550 are separated asshown because of their location within the laser tracker. In anembodiment, the payload functions 1530 are located in a payload, whilethe azimuth encoder electronics is located in the azimuth assembly andthe zenith encoder electronics 1550 is located in the zenith assembly.

Many types of peripheral devices are possible, but here three suchdevices are shown: a temperature sensor 1582, a six-DOF probe 1584, anda personal digital assistant, 1586, which might be a smart phone, forexample. The laser tracker may communicate with peripheral devices in avariety of means, including wireless communication over the antenna1572, by means of a vision system such as a camera, and by means ofdistance and angular readings of the laser tracker to a cooperativetarget such as the six-DOF probe 1584.

In an embodiment, a separate communications bus goes from the masterprocessor 1520 to each of the electronics units 1530, 1540, 1550, 1560,1565, and 1570. Each communications line may have, for example, threeserial lines that include the data line, clock line, and frame line. Theframe line indicates whether or not the electronics unit should payattention to the clock line. If it indicates that attention should begiven, the electronics unit reads the current value of the data line ateach clock signal. The clock signal may correspond, for example, to arising edge of a clock pulse. In an embodiment, information istransmitted over the data line in the form of a packet. In anembodiment, each packet includes an address, a numeric value, a datamessage, and a checksum. The address indicates where, within theelectronics unit, the data message is to be directed. The location may,for example, correspond to a processor subroutine within the electronicsunit. The numeric value indicates the length of the data message. Thedata message contains data or instructions for the electronics unit tocarry out. The checksum is a numeric value that is used to minimize thechance that errors are transmitted over the communications line.

In an embodiment, the master processor 1520 sends packets of informationover bus 1610 to payload functions electronics 1530, over bus 1611 toazimuth encoder electronics 1540, over bus 1612 to zenith encoderelectronics 1550, over bus 1613 to display and UI electronics 1560, overbus 1614 to removable storage hardware 1565, and over bus 1616 to RFIDand wireless electronics 1570.

In an embodiment, master processor 1520 also sends a synch(synchronization) pulse over the synch bus 1630 to each of theelectronics units at the same time. The synch pulse provides a way ofsynchronizing values collected by the measurement functions of the lasertracker. For example, the azimuth encoder electronics 1540 and thezenith electronics 1550 latch their encoder values as soon as the synchpulse is received. Similarly, the payload functions electronics 1530latch the data collected by the electronics contained within thepayload. The six-DOF, ADM, and position detector all latch data when thesynch pulse is given. In most cases, the camera and inclinometer collectdata at a slower rate than the synch pulse rate but may latch data atmultiples of the synch pulse period.

The laser tracker electronics processing system 1510 may communicatewith an external computer 1590, or it may provide computation, display,and UI functions within the laser tracker. The laser trackercommunicates with computer 1590 over communications link 1606, whichmight be, for example, and Ethernet line or a wireless connection. Thelaser tracker may also communicate with other elements 1600, representedby the cloud, over communications link 1602, which might include one ormore electrical cables, such as Ethernet cables, and one or morewireless connections. An example of an element 1600 is another threedimensional test instrument—for example, an articulated arm CMM, whichmay be relocated by the laser tracker. A communication link 1604 betweenthe computer 1590 and the elements 1600 may be wired (e.g., Ethernet) orwireless. An operator sitting on a remote computer 1590 may make aconnection to the Internet, represented by the cloud 1600, over anEthernet or wireless line, which in turn connects to the masterprocessor 1520 over an Ethernet or wireless line. In this way, a usermay control the action of a remote laser tracker.

FIG. 7 is a flow diagram showing steps 700 in an embodiment formeasuring with a system. Step 705 is to provide a system that includes acollection of retroreflector targets and a laser tracker. The collectionof retroreflector targets include at least three retroreflector targets,a first target, a second target, and a third target, those targets notaligned in a straight line. The laser tracker is in a first frame ofreference, which is shown in FIGS. 1, 5, and 6 as a frame of reference30. In an embodiment, the origin of the frame of reference of the lasertracker is at a gimbal point 22 of the laser tracker. The x, y, and zaxes of the first frame of reference are fixed with respect to thetracker surroundings, but are usually referenced to trackercharacteristics such as directions of rotation. The laser trackerincludes a structure, a first light source, an absolute distance meter,a first angular transducer, a second angular transducer, a trackingsystem, a first camera, a second light source, and a processor. Thestructure is rotatable about a first axis and a second axis. In anembodiment, the first axis is an azimuth axis and the second axis is azenith axis. In an embodiment, the structure is a payload that holdsoptical components. In another embodiment, the structure is a mirrorthat deflects light to send the light out of the laser tracker in adesired direction. The first light source, which produces a first lightbeam, may be a laser, a superluminescent diode, or another type of lightsource. The absolute distance meter cooperates with the first lightsource to measure an absolute distance. The light from the first lightsource may be used to measure the time taken for the light, traveling atthe speed of light through air to a retroreflector target and back tothe tracker. The method of measuring the time of flight may include aphase-measurement method, a pulsed time-of-flight method, or any othertype of absolute distance measurement method. In an embodiment, thefirst and second angular transducers may be angular encoders thatmeasure azimuth and zenith angles. The tracking system is used to keepthe first light beam centered on a retroreflector target. Aretroreflector has a position about which a beam of light reflects. Forexample, in a cube-corner retroreflector, light reflects symmetricallyabout the vertex of the cube corner, which is the point about which thethree mutually perpendicular surfaces intersect. In many cases, thepoint at which light reflects symmetrically is centered in a sphere. Forexample, in a type of spherically mounted retroreflector, the vertex ofan open-air cube corner is placed at the center of a steel sphere. Inthis case, the tracking system of the laser tracker keeps the first beamof light centered on a center of the retroreflector target. However, aretroreflector target is not necessarily centered in a sphere. Rather aretroreflector may be directly attached to an object under test withoutplacing it in a sphere. In this case, the term “center” is meant torefer to the point of the retroreflector about which the first beam oflight reflects symmetrically, even if it does not refer to a center ofany object. The tracking system of the laser tracker may keep a portionof the reflected light centered on a position detector within the lasertracker, the position detector being, for example, a position sensitivedetector or a photosensitive array. The laser tracker includes a firstcamera, which in an embodiment is mounted on an exterior surface of apayload of a tracker, the payload capable of rotation about the firstaxis and a second axis. In other embodiments, the first camera may belocated inside the laser tracker and may view a scene external to thelaser tracker, the scene centered about an optical axis of the lasertracker. In other embodiments the first camera may be located at otherpositions relative on or within the laser tracker. The first cameraincludes a first lens and a first photosensitive array. The first lensproduces an image on the first photosensitive array of objects externalto the laser tracker. A second light source, which in most cases isproximate to the first camera, emits a second beam of light. This lighttravels to retroreflector targets, which are a part of a collection ofretroreflector targets. A portion of the second beam of light reflectsoff the retroreflectors and returns to the first camera, which imagesthe reflected light on the first photosensitive array. A processor maybe located in the laser tracker, in a companion electrical unit 50, inan external unit 60, or in a combination of locations. The processor mayinclude a combination of processing elements including microprocessors,digital processing units, field programmable gate arrays, and memories.The processor is configured to operate the laser tracker.

Step 710 is to store a list of nominal coordinates for the first target,the second target, the third target, and at least one additional point.The nominal coordinates are three-dimensional coordinates given in asecond frame of reference. The second frame of reference is associatedwith an object under test or with a structure to which the object undertest is attached. An examples of a second frame of reference 40 is shownin FIGS. 1, 5, and 6. In general, the x, y, and z axes of the secondframe of reference may be rotated with respect to the x, y, and z axesof the first frame of reference.

Step 715 is to capture on the first photosensitive array a portion ofthe light emitted by the second light beam and reflected off the firsttarget, the second target, and the third target.

Step 720 is to obtain spot positions on the photosensitive array fromthe portion of light reflected off the first target, the second target,and the third target. The spot positions may, for example, be centroidsof the spots for the first target, the second target, and the thirdtarget.

Step 725 is to determine a correspondence between a first spot position,a second spot position, and a third spot position on the firstphotosensitive array and the nominal coordinates of the first target,the second target, and the third target, respectively. Such acorrespondence may be obtained in a variety of ways, for example,according to the methods of described in the claims herein below. Onesuch method includes observing the possible correspondences within anallowable range of orientations of the second frame of reference withthe first frame of reference. Another method involves using atriangulation method with two (stereo) cameras located on the lasertracker. Another method involves using a single tracker camera butrotating the tracker to two different orientations. With this method,the two images obtained on the camera photosensitive array are used todetermine the correspondence. Measurements can also be made with thefirst camera in frontsight and backsight modes and the images obtainedon the first photosensitive array used to determine the correspondence.The relative positions of first and second frames of reference may bechanged, and the resulting pattern of spots on the first photosensitivearray used to determine the correspondence. For example, the secondframe of reference may be associated with a moving carriage, as shown inFIGS. 5 and 6, so that the first camera can obtain two different imagesas at different relative positions of the first and second frames ofreference. In an embodiment, a general mathematical approach that may beundertaken to determine a correspondence between the first, second, andthird spots on a photosensitive array and the nominal coordinates offirst, second, and third targets involves constructing a transformationmatrix to transform coordinates from frame of reference 2 to frame ofreference 1 or vice versa, as discussed hereinabove and in the claimsherein below. For an image obtained by a photosensitive array, thepoints on the array, may be projected from a location on thephotosensitive array, through a perspective center of the lens, and intoobject space. In this way, the spots on a first photosensitive array maybe converted into angles. If a second photosensitive array is available,with a known distance between the first and second photosensitivearrays, a triangulation procedure may be used to determine the positionof each of the three targets, by methods that are well known to thoseskilled in the art. If only a single camera is available, atriangulation method may still be applied by obtaining frontsight andbacksight images since the position of the camera is reversed to theopposite side of the tracker optical axis in going from frontsight tobacksight modes. The distance between the camera positions in frontsightand backsight modes is known, so that the procedure is equivalent to astereo triangulation procedure. Similarly, but rotating the trackerstructure to two different angles (about the first axis, the secondaxis, or both), two different views can be obtained, and a methodsimilar to a triangulation procedure may be used, as explainedhereinabove and in '033. The method of constraints, in which theapproximate relative orientations between the first and second frames ofreference are known does not in general permit a direct solution foreach of the three-dimensional coordinates of the first, second, andthird targets, but in most cases it enables to positions to be localizedwell enough to draw a correspondence between the three spots and thenominal coordinates of the first, second, and third targets.

Step 730 is to direct the first beam of light to the first target basedat least in part on the nominal coordinates of the first target and thefirst spot position and to measure the three-dimensional coordinates ofthe first target using the absolute distance meter, the first angulartransducer, and the second angular transducer. As explained in step 720,some of the methods of obtaining correspondences yield three-dimensionalcoordinates with respect to the first frame of reference so thatdirecting the laser beam to the first, second, and third targets isstraightforward. In the case in which the directions are based on theconstraints between the first and second frames of reference, theoptimal directions to the first, second, and third targets may not beknown to high precision; however, a direction can be obtained byassuming a distance to the target. The resulting direction is generallyclose enough to the optimal direction to enable the target to becaptured, for example, by means of the methods describe in claims hereinbelow. The measured three-dimensional coordinates are in the first frameof reference, which is the frame of reference of the laser tracker.

Step 735 is the same as step 730, only applied to the second targetrather than the first target. Step 740 is the same as step 735, onlyapplied to the third target rather than the first target.

Step 745 is to determine three-dimensional coordinates of the at leastone additional point in the first frame of reference based at least inpart on the measured three-dimensional coordinates of the first target,the second target, the third target, and the nominal coordinates of theat least one additional point. This is a mathematical step, which may becarried out, for example, by obtaining a transformation matrix thatenables calculation of any nominal coordinate (three dimensionalcoordinate within the second frame of reference) into athree-dimensional coordinate within the first (tracker) frame ofreference. The three-dimensional coordinates obtained in steps 725, 730,and 735 are sufficient to determine the transformation matrix, usingmethods that are well known to those skilled in the art.

Step 750 is to store the three-dimensional coordinates of the at leastone additional point. The coordinates may be stored in electronicreadable media, in a computer memory, or in a microprocessor, forexample. Step 755 is the end of the method having the steps 700.

FIG. 8 is a flow diagram showing steps 800 in an embodiment formeasuring with a system. The steps of 800 follow at point A, labeled755, in FIG. 7. Step 805 is to direct a light beam to the at least oneadditional point. The laser tracker may carry out this stepautomatically.

Step 810 is to place a selected retroreflector target to intercept thefirst light beam. One way to do this is for the operator to move ahandheld selected retroreflector target into the first beam of light. Asecond way to do this is to place the selected retroreflector target ona nest, for example, a magnetic nest, mounted on an object under test.If the three-dimensional coordinates of the at least one additionalpoint is the known accurately enough, the first laser beam will bedirected well enough that at least a portion of the beam will becaptured by the clear aperture of the selected retroreflector target.

Step 815 is to direct the first light beam to the center of the selectedretroreflector target. This step is performed by the tracking system ofthe laser tracker. Step 820 is to measure three-dimensional coordinatesof the selected retroreflector target using the absolute distance meter,the first angular transducer, and the second angular transducer. Themethod 800 ends with step 825.

FIG. 9 is a flow diagram showing steps 900 in an embodiment formeasuring with a system. The steps of 900 follow at a point A, labeled755, in FIG. 7. Step 905 is to direct the first light beam to the atleast one additional point.

The step 910 is to move the first light beam in a first pattern inspace, the first pattern proximate to the at least one additional point.Such a first pattern is usually referred to as a search pattern. As anexample, the light beam may begin at an initial position and then movein a spiral pattern outward.

Step 915 is to detect the light beam with the tracking system of thelaser tracker. This may occur when a portion of the first beam of lightreflected off a retroreflector strikes a position detector. Thisdetecting of light by the position detector indicates that the firstlight beam has intercepted the clear aperture of the retroreflectortarget.

Step 920 is to direct the first light beam to a center of the selectedretroreflector target. As explained above, the center in this contextrefers to a position relative to the retroreflector target about whichlight beams reflect symmetrically. The term center in this context doesnot necessarily refer to a physical center of the retroreflector target.

Step 925 is to measure three-dimensional coordinates of the selectedretroreflector target using the absolute distance meter, the firstangular transducer, and the second angular transducer. The method ofstep 900 ends with step 930.

FIG. 10 is a flow diagram showing steps 1000 in an embodiment formeasuring with a system. The steps of 1000 follow at a point A, labeled755, in FIG. 7. Step 1005 is to provide a third camera and a fourthlight source, the third camera including a third lens system and a thirdphotosensitive array, the third camera having a field of view smallerthan the field of view of the first camera, the fourth light sourceproviding a fourth light beam.

Step 1010 is to capture on the third photosensitive array a portion ofthe light emitted by the fourth light source and reflected off the firsttarget, the second target, and the third target. Images of the firsttarget, the second target and the third target were already obtainedwith the first camera. Now additional measurements are collected using athird camera. In some cases, the information obtained from the firstcamera may be used to steer the laser tracker to a position enabling thesecond camera to view the first, second, or third target.

Step 1015 is to obtain spot positions on the photosensitive array fromthe portion of light reflected off each of the first target, secondtarget, and the third target. Such spot positions may be obtained, forexample, as centroids of each of the spots.

Step 1020 is to determine a correspondence between a first spotposition, a second spot position, and a third spot position on the thirdphotosensitive array and the nominal coordinates of the first target,the second target, and the third target, respectively. The methods fordetermining a correspondence are the same as those discussed hereinabove, but relatively more accurate information provided by the thirdcamera, which has a narrower field of view than the first camera. Themethod 1000 ends with step 1025.

FIG. 11 is a flow diagram showing steps 1100 in an embodiment formeasuring with a system. The steps of 1100 follow at a point A, labeled755, in FIG. 7.

Steps 1105 is to direct the first light beam to a plurality ofadditional points, the plurality of additional points including thefirst additional point, the plurality of additional points indicative ofactions to be taken by an operator. In this way, the laser tracker isable to direct the action of an operator.

FIG. 12 is a flow diagram showing steps 1200 in an embodiment formeasuring with a system. The steps of 1200 follow at a point B, labeled825, in FIG. 8. Step 1205 is to measure according to an inspection plan.A typical inspection plan may include a variety of points that are to bemeasured. Some of the points may be on the surface of an object, whileother points may be in nests. Some of the points may be measureddiscretely, while other points are measured in a scan pattern overdesignated surfaces.

FIG. 13 is a flow diagram showing steps 1300 in an embodiment formeasuring with a system. The steps of 1300 follow at a point A, labeled755, in FIG. 7. Step 1305 is to direct the first light beam to the atleast one additional point. Step 1310 is to perform an assemblyoperation at a position of the first light beam. An assembly operationmay include drilling screwing, sanding, puttying, milling, or any otheroperation intended to modify the object or add to the object. Forexample, the first light beam might indicate a location on the objectfor which a hole is to be drilled.

FIG. 14 is a flow diagram showing steps 1400 in an embodiment formeasuring with a system. The steps of 1400 follow at a point B, labeled825, in FIG. 8. Step 1405 is to provide an inspection plan havinginspection points to be measured by the laser tracker. Step 1410 is toaffix at least one retroreflector target to an object under test. Such aretroreflector target serves in effect as a drift monument enabling astability check of the system. Step 1415 is to provide a maximumallowable movement for the three-dimensional coordinates of the at leastone retroreflector target affixed to the object under test. The maximumallowable movement is a numerical value provided by the user based onthe required stability. The step 1020 is to measure thethree-dimensional coordinates of the at least one retroreflector targetaffixed to the object under test, the measuring performed at a firsttime and at a second time. The step 1025 is to determine a first changein the three-dimensional coordinates of the at least one retroreflectortarget from the first time to the second time. In a highly stablesystem, these coordinates will change by a small amount. If either theobject under test or the laser tracker is bumped, the measurements cansuddenly change, thereby introducing errors. Similarly, if thetemperature of the environment changes significantly, the dimensions ofthe object may change, the performance of the tracker may degrade, orthe properties of the air through which the first light beam propagatesmay change. Any of these changes may degrade the accuracy ofmeasurements. The step 1030 is to take an action when the first changeexceeds the maximum allowable movement. The action may include measuringat least three retroreflectors on the object under test to re-establishthe three-dimensional coordinates of the inspection points. It may alsoinclude notifying an operator that the first change has exceeded themaximum allowable movement. This might prompt the operator tore-compensate the laser tracker, check the stability of the object undertest and the laser tracker, or take other steps. The method 1400 ends atstep 1435.

FIG. 15 is a flow diagram showing steps 1700 in an embodiment formeasuring with a system. The steps of 1700 follow at a point A, labeled755, in FIG. 7. Step 1705 is to provide a maximum allowable discrepancy.This is a value provided by the user. Step 1710 is to provide acoefficient of thermal expansion (CTE) for the object under test and areference temperature. As an example, if the material is steel, a CTE of11.5 micrometers/meter/° C. may be provided. The reference temperaturemight be the widely used value of 20° C. Step 1715 is to place a firstreference retroreflector and a second reference retroreflector on theobject under test, there being a first distance between the firstreference retroreflector and the second reference retroreflector at thereference temperature. Step 1720 is to measure a temperature of theobject under test. Step 1725 is to calculate a first temperaturedifference by subtracting the reference temperature from the measuredtemperature of the object under test. Step 1730 is to calculate a scalefactor by multiplying the first temperature difference by thecoefficient of thermal expansion. This gives a value in units ofmicrometers/meter, for example. In other words, the scale factor is adimensionless quantity. Step 1735 is to measure the 3D coordinates ofthe first and second reference retroreflectors using the absolutedistance meter, the first angular transducer, and the second angulartransducer. Step 1740 is to calculate a second distance extending fromthe measured 3D coordinates of the first reference retroreflector to themeasured 3D coordinates of the second reference retroreflector. Step1745 is to calculate a third distance by subtracting the first distancefrom the second distance. Step 1750 is to calculate a fourth distance bymultiplying the first distance by the scale factor. Step 1755 is tocalculate a discrepancy value by subtracting the third distance from thefourth distance. Step 1760 is to take an action when the discrepancyvalue exceeds the maximum allowable discrepancy, the action being eitherissuing an alarm or measuring coordinates from among at least someretroreflector targets from among the collection of retroreflectortargets and, from this data, re-establishing a frame of reference for anobject. The purpose of the steps 1700 is to check the consistency ofthermal length compensations to directly measured length differences. Ifthe changes in length do not match, there is the chance that thetemperature measurement is not valid, the CTE value is not givencorrectly, or there is some other problem. With this problem identifies,additional steps can be taken.

As will be appreciated by one skilled in the art, aspects of the presentinvention may be embodied as a system, method, or computer programproduct. Accordingly, aspects of the present invention may take the formof an entirely hardware embodiment, an entirely software embodiment(including firmware, resident software, micro-code, etc.) or anembodiment combining software and hardware aspects that may allgenerally be referred to herein as a “circuit,” “module” or “system.”Furthermore, aspects of the present invention may take the form of acomputer program product embodied in one or more computer readablemedium(s) having computer readable program code embodied thereon.

Any combination of one or more computer readable medium(s) may beutilized. The computer readable medium may be a computer readable signalmedium or a computer readable storage medium. A computer readablestorage medium may be, for example, but not limited to, an electronic,magnetic, optical, electromagnetic, infrared, or semiconductor system,apparatus, or device, or any suitable combination of the foregoing. Morespecific examples (a non-exhaustive list) of the computer readablemedium would include the following: an electrical connection having oneor more wires, a portable computer diskette, a hard disk, a randomaccess memory (RAM), a read-only memory (ROM), an erasable programmableread-only memory (EPROM or Flash memory), an optical fiber, a portablecompact disc read-only memory (CD-ROM), an optical storage device, amagnetic storage device, or any suitable combination of the foregoing.In the context of this document, a computer readable storage medium maybe any tangible medium that may contain, or store a program for use byor in connection with an instruction execution system, apparatus, ordevice.

Any combination of one or more computer readable medium(s) may beutilized. The computer readable medium may be a computer readable signalmedium or a computer readable storage medium. A computer readablestorage medium may be, for example, but not limited to, an electronic,magnetic, optical, electromagnetic, infrared, or semiconductor system,apparatus, or device, or any suitable combination of the foregoing. Morespecific examples (a non-exhaustive list) of the computer readablemedium would include the following: an electrical connection having oneor more wires, a portable computer diskette, a hard disk, a randomaccess memory (RAM), a read-only memory (ROM), an erasable programmableread-only memory (EPROM or Flash memory), an optical fiber, a portablecompact disc read-only memory (CD-ROM), an optical storage device, amagnetic storage device, or any suitable combination of the foregoing.In the context of this document, a computer readable storage medium maybe any tangible medium that may contain, or store a program for use byor in connection with an instruction execution system, apparatus, ordevice.

A computer readable signal medium may include a propagated data signalwith computer readable program code embodied therein, for example, inbaseband or as part of a carrier wave. Such a propagated signal may takeany of a variety of forms, including, but not limited to,electro-magnetic, optical, or any suitable combination thereof. Acomputer readable signal medium may be any computer readable medium thatis not a computer readable storage medium and that can communicate,propagate, or transport a program for use by or in connection with aninstruction execution system, apparatus, or device.

Program code embodied on a computer readable medium may be transmittedusing any appropriate medium, including but not limited to wireless,wireline, optical fiber cable, RF, etc., or any suitable combination ofthe foregoing.

Computer program code for carrying out operations for aspects of thepresent invention may be written in any combination of one or moreprogramming languages, including an object oriented programming languagesuch as Java, Smalltalk, C++, C# or the like and conventional proceduralprogramming languages, such as the “C” programming language or similarprogramming languages. The program code may execute entirely on theuser's computer, partly on the user's computer, as a stand-alonesoftware package, partly on the user's computer and partly on a remotecomputer or entirely on the remote computer or server. In the latterscenario, the remote computer may be connected to the user's computerthrough any type of network, including a local area network (LAN) or awide area network (WAN), or the connection may be made to an externalcomputer (for example, through the Internet using an Internet ServiceProvider). Aspects of the present invention are described with referenceto flowchart illustrations and/or block diagrams of methods, apparatus(systems) and computer program products according to embodiments of theinvention. It will be understood that each block of the flowchartillustrations and/or block diagrams, and combinations of blocks in theflowchart illustrations and/or block diagrams, may be implemented bycomputer program instructions.

These computer program instructions may be provided to a processor of ageneral purpose computer, special purpose computer, or otherprogrammable data processing apparatus to produce a machine, such thatthe instructions, which execute via the processor of the computer orother programmable data processing apparatus, create means forimplementing the functions/acts specified in the flowchart and/or blockdiagram block or blocks. These computer program instructions may also bestored in a computer readable medium that may direct a computer, otherprogrammable data processing apparatus, or other devices to function ina particular manner, such that the instructions stored in the computerreadable medium produce an article of manufacture including instructionswhich implement the function/act specified in the flowchart and/or blockdiagram block or blocks.

The computer program instructions may also be loaded onto a computer,other programmable data processing apparatus, or other devices to causea series of operational steps to be performed on the computer, otherprogrammable apparatus or other devices to produce a computerimplemented process such that the instructions which execute on thecomputer or other programmable apparatus provide processes forimplementing the functions/acts specified in the flowchart and/or blockdiagram block or blocks.

Any flowcharts and block diagrams in the Figures illustrate thearchitecture, functionality, and operation of possible implementationsof systems, methods, and computer program products according to variousembodiments of the present invention. In this regard, each block in theflowchart or block diagrams may represent a module, segment, or portionof code, which comprises one or more executable instructions forimplementing the specified logical function(s). It should also be notedthat, in some alternative implementations, the functions noted in theblock may occur out of the order noted in the Figures. For example, twoblocks shown in succession may, in fact, be executed substantiallyconcurrently, or the blocks may sometimes be executed in the reverseorder, depending upon the functionality involved. It will also be notedthat each block of the block diagrams and/or flowchart illustration, andcombinations of blocks in the block diagrams and/or flowchartillustration, may be implemented by special purpose hardware-basedsystems that perform the specified functions or acts, or combinations ofspecial purpose hardware and computer instructions.

While preferred embodiments have been shown and described, variousmodifications and substitutions may be made thereto without departingfrom the spirit and scope of the invention. Accordingly, it is to beunderstood that the present invention has been described by way ofillustrations and not limitation.

The presently disclosed embodiments are therefore to be considered inall respects as illustrative and not restrictive, the scope of theinvention being indicated by the appended claims, rather than theforegoing description, and all changes which come within the meaning andrange of equivalency of the claims are therefore intended to be embracedtherein.

What is claimed is:
 1. A method for measuring with a system, the methodcomprising steps of: providing the system including a collection ofretroreflector targets and a laser tracker, the collection ofretroreflector targets including at least three non-collinearretroreflector targets, the at least three non-collinear retroreflectortargets including a first target, a second target, and a third target,the laser tracker in a first frame of reference fixed with respect totracker surroundings, the laser tracker having a structure, a firstlight source, an absolute distance meter, a first angular transducer, asecond angular transducer, a tracking system, a first camera, a secondlight source, and a processor, the structure rotatable about a firstaxis and a second axis, the first light source producing a first lightbeam that cooperates with the absolute distance meter, the first angulartransducer measuring a first angle of rotation about the first axis, thesecond angular transducer measuring a second angle of rotation about thesecond axis, the tracking system configured to move the first light beamto a center of any retroreflector target from among the collection ofretroreflector targets, the first camera including a first lens systemand a first photosensitive array, the second light source providing asecond light beam, and the processor configured to operate the lasertracker; storing a list of nominal coordinates for the first target, thesecond target, the third target, and at least one additional point, thenominal coordinates being three-dimensional coordinates in a secondframe of reference; capturing on the first photosensitive array aportion of the light emitted by the second light beam and reflected offthe first target, the second target, and the third target; obtainingspot positions on the photosensitive array from the portion of lightreflected off each of the first target, second target, and the thirdtarget; determining a correspondence between a first spot position, asecond spot position, and a third spot position on the firstphotosensitive array and the nominal coordinates of the first target,the second target, and the third target, respectively; directing thefirst beam of light to the first target based at least in part on thenominal coordinates of the first target and the first spot position;measuring three-dimensional coordinates of the first target using theabsolute distance meter, the first angular transducer, and the secondangular transducer; directing the first beam of light to the secondtarget based at least in part on the nominal coordinates of the secondtarget and the second spot position; measuring three-dimensionalcoordinates of the second target using the absolute distance meter, thefirst angular transducer, and the second angular transducer; directingthe first beam of light to the third target based at least in part onthe nominal coordinates of the third target and the third spot position;measuring three-dimensional coordinates of the third target using theabsolute distance meter, the first angular transducer, and the secondangular transducer; determining three-dimensional coordinates of the atleast one additional point in the first frame of reference based atleast in part on the measured three-dimensional coordinates of the firsttarget, the second target, the third target, and the nominal coordinatesof the at least one additional point; storing the determinedthree-dimensional coordinates of the at least one additional point;providing a maximum allowable discrepancy; providing a coefficient ofthermal expansion for an object under test; providing a referencetemperature; placing a first reference retroreflector and a secondreference retroreflector on the object under test, there being a firstdistance between the first reference retroreflector and the secondreference retroreflector at the reference temperature; measuring atemperature of the object under test; calculating a first temperaturedifference by subtracting the reference temperature from the measuredtemperature of the object under test; calculating a scale factor bymultiplying the first temperature difference by the coefficient ofthermal expansion; measuring the three-dimensional coordinates of thefirst reference retroreflector using the absolute distance meter, thefirst angular transducer, and the second angular transducer; measuringthe three-dimensional coordinates of the second reference retroreflectorusing the absolute distance meter, the first angular transducer, and thesecond angular transducer; calculating a second distance extending fromthe measured three-dimensional coordinates of the first referenceretroreflector to the measured three-dimensional coordinates of thesecond reference retroreflector; calculating a third distance bysubtracting the first distance from the second distance; calculating afourth distance by multiplying the scale factor by the first distance;calculating a discrepancy value by subtracting the third distance fromthe fourth distance; and taking an action when the discrepancy valueexceeds the maximum allowable discrepancy, the action being eitherissuing an alarm or measuring the three-dimensional coordinates at leastsome retroreflector targets from among the collection of retroreflectortargets and, from this data, re-establishing a frame of reference for anobject under test.